The importance of maintaining a hygienic process environment to ensure product quality and purity as a food, dairy, or beverage processor, this is where a good Clean-in-place (CIP) system comes in handy.Because of the need to keep processing components free of bacteria, CIP systems play an important role in processing. Cleaning is done in process piping, tanks, heat exchangers, and other equipment to prevent product contamination and to keep the process running efficiently.
ADVANTAGES OF CIP
- Reduces human error: Cleaning automation reduces the possibility of human error that can contribute to an unsafe product.
- Keeps employees safe: By containing cleaning solutions within the system, the system reduces chemical exposure.
- More productivity: As less time is lost to cleaning, more time is spent producing product.
- Product quality: Reliable and repeatable cleaning means consistent and long-lasting product quality. Fewer product recalls and increased brand confidence result from less contamination.
- Water and energy consumption are reduced due to repeatable cycle control.
5 STEPS OF CIP IN FOOD AND BEVERAGES
1ST STEP- PRE- RINSE: Because a well-monitored and well-executed pre-rinse makes the rest of the wash cycle predictable and repeatable, it is a critical step in the CIP process.
The cycle of pre-rinse:
- Wets the inside of the lines and tanks.
- Removes the vast majority of the remaining residue
- Sugars are dissolved, and fats are partially melted.
- Non-chemical pressure testing of the CIP flow path is provided.
Use potable plant water, de-ionized water (DI), reverse osmosis (RO) water, or re-use the final rinse solution from the previous cleaning sequence. To ensure that the pre-rinse effectively removes all solids, a turbidity sensor can be used.
2ND STEP- CAUSTIC WASH: Caustic washes soothe fats, allowing them to be removed more easily. The alkali used during caustic washes, also known as caustic soda, sodium hydroxide, or NaOH, has a very high pH in a concentration range of 0.5-2.0 percent. For heavily soiled surfaces, concentrations as high as 4% may be used.
In most CIP wash cycles, caustic is used as the primary detergent. A non-foaming formulation can assist in reducing pump cavitation and increasing efficiency. It will also keep tanks from becoming overfilled with foam when the system begins to recirculate.
3RD STEP-INTERMEDIATE RINSE: Fresh water flushes out any remaining traces of detergent from the caustic wash.Proper cleaning is ensured by using proper instrumentation during each step of the CIP Cycle, including rinsing.Level transmitters and probes are used to monitor the levels of wash and rinse tanks.Flow transmitters ensure that spray devices have enough flow to precisely control the wash and rinse steps.Conductivity transmitters ensure that chemical levels stay within a predetermined range.
4TH STEP-FINAL RINSE: To flush residual cleaning agents, rinse with DI, RO, or city water.
The final rinse water in many systems can be recovered and reused as the pre-rinse solution for the next cleaning cycle. The residual heat and chemicals from the final rinse will make the next pre-rinse more effective and cost-effective.
5TH STEP-SANITIZING RINSE: It may be necessary to assist in the killing of microorganisms before beginning the next production run. Various hypochlorite solutions (potassium, sodium, or calcium), also known as "hypo," have been used as sanitizers in many CIP cycles for many years.
A sanitising rinse's active ingredient is chlorine (bleach), which is-
- It is relatively cheap to use.
- Excellent sanitising rinse for soils prone to bacterial growth, such as dairy products.
- Stainless steel may be harmed by this chemical, which causes staining, corrosion, and pitting.
In recent years, more sanitation managers have abandoned bleach-based sanitizers in favour of per acetic acid (PAA), a mix of hydrogen peroxide and acetic acid.
- Even at low temperatures, it is a powerful disinfectant.
- The chlorine residue is rinsed away, leaving little to no chlorine residue to corrode stainless steel.
- Is effective against all types of microorganisms, including spoilage organisms, pathogens, and bacterial spores.
- It has also been shown to be more environmentally friendly in the wastewater stream.
- It has a strong, pungent odour and should be used only in well-ventilated areas.